Hello,
I am not a professional shaper and maybe somethings i will say are very wrong, but this is my process.
I am not including lamination here.
Not very detailed but follows a step by step aproach, you can check every step on youtube and can get tables of measurements from greenlight
Pu blanks can be laminated with epoxy or pe resin
Eps blanks can only be laminated with epoxy resin
Most common easy to work cheap material is fiberglass cloth, but there are alternatives.
Most blanks come with natural rocker and a bit concave (using this kind of blank is a huge help)
Shaping the blank: (need electric planer, sand blocks,mini planer for stringer, scissor calipers for thickness, ruler, shaper square, handsaw and a pencil) not all essencial but they help, you can not use some and replace some.
1-download outline template (blending curves or shape3dx wharehouse are my go to places) print them in thicker paper or glue it to plywood 3 mil and cut the template.
2- consider the tail and nose rocker you will be wanting in your board.
3- consider the neasurements for your board.
4- chose a blank longer and wider with enough rocker curve for the tail and nose measurements you wish. For safekeep make it 4" to 6" longer and 1 1/2" inches wider.
5- start working, bottom of the board, measure the thickness of the blank on the midpoint and calculate how much you need to bring down to get the desired thickness.
6- (not professional at all, but works for me)
turn the board to bottom, set a long piece of wood over the stringer and try to find aproximate nose and tail rocker within the size of board you want to build, then mark those lines perpendicular to the blank.
Mark the template you printed and take a good look at it because that is your surfboard outline, it will look like that(check, measure, make sure its allright), mark the midlle point, and now if you want more volume on the front move this middle point foward,(or do the oposite push the thickest point backwards) trace a line in the rail side from that line on both sides of the blank. That line is where you will be measuring thickness
7-Start planing the bottom, if you want to bring the foam down for exemple 10 mil pass the planner set for 2 or 3 mil once, bring stringer down with mini planer and erase the lines with the sanding block, after repeat pass planer again etc… untill you reach the desired thickness.
8- turn the board, plane not much (keep foam on the deck )and clean.
9- back to the bottom of the board, mark your outline again and cut it.
10- do your rail marks. (Greenlight tables), start with the tuck mark on the bottom.
11- do your concaves and shape the rails. Pay special atention to the edge it finishes arround 20 cms above end of side fins, the bottom of the rail stays square 90 degres and then starts rolling to round direction nose of the board.
12-bring down excess foam from nose and tail
12- mark fins ( shaper square helps not required).
Chears and good waves.
